EnerSys IRONCLAD Charger Battery

Specifications:

• Nominal capacity C5:
• Nominal voltage:
• Discharge current:
• Nominal S.G. of electrolyte Type PzQ:
• Rated temperature:
• Nominal electrolyte level:

Product Usage Instructions

1. Commissioning Filled and Charged Batteries
   The battery should be inspected to ensure it is in perfect physical condition; the battery harness must have reliable contact and must be connected with correct polarity. Use only original bolts for assembly of cables and harness cables. Tighten the harness and connector bolts to the recommended torque settings.

2.  Operation
   Refer to EN 62485-3 Safety requirements for secondary batteries and battery installations-Traction batteries for standard operation guidelines, especially in industrial trucks.

3.  Discharging
   Follow recommended guidelines for discharging the battery safely and efficiently.

4.  Charging
   Charge the battery following the EN 62485-3 standard. Keep the vent plugs closed during charging. Connect the battery with the charger switched off, ensuring correct polarity, and then switch on the charger.

5.  Equalizing Charge
   Perform equalizing charges after deep discharges or incomplete recharges to safeguard the battery’s life and maintain capacity. Observe the charging current limits and monitor the temperature during equalizing charges.

6. Maintenance
   Charge the battery after every discharge. Monitor the electrolyte level to ensure it does not fall below the specified mark. Avoid adding water in the first 10 cycles of use. For batteries with filling level sensors, observe the LED indicator daily.

Frequently Asked Questions (FAQ):

• Q: What should I do if I notice a drop in the electrolyte level?
  A: If you notice a drop in the electrolyte level, do not add water in the first 10 cycles. Monitor the level closely and consult the maintenance guidelines in the manual.

• Q: How often should I perform equalizing charges?
  A: Equalizing charges should be performed after deep discharges, repeated incomplete recharges, and charges to an IU characteristic curve. Follow the recommended guidelines for maintaining battery capacity.

OWNER’S MANUAL

www.enersys.com

INTRODUCTION

• The information contained in this document is critical for safe handling and proper use of the IRONCLAD® battery for powering electrical industrial trucks. It contains a global system specification as well as related safety measures, codes of behavior, a guideline for commissioning and recommended maintenance. This document must be retained and available for users working with and responsible for the battery. All users are responsible for ensuring that all applications of the system are appropriate and safe, based on conditions anticipated or encountered during operation.
• This owner’s manual contains important safety instructions. Read and understand  the sections on safety and operation of the battery before operating the battery and the equipment into which it is installed.
• It is the owner’s responsibility to ensure the use of the documentation and any activities related thereto, and to follow all legal requirements applicable to themselves and the applications in the respective countries.
• This owner’s manual is not intended to substitute for any training  on handling and operating the industrial truck or IRONCLAD® battery that may be required by local laws and/or industry standards.
• Proper instruction and training of all users must be ensured prior to any contact with the battery system.
• For service, contact your sales representative or call:
  • EnerSys EMEA
  • EH Europe GmbH Baarerstrasse 18 6300 Zug, Switzerland Tel: +41 44 215 74 10
  • www.enersys.com
  • EnerSys Asia
  • 152 Beach Road

  • 11-08 Gateway East Building Singapore 189721

  • Tel: +65 6416 4800
• Your Safety and the Safety of Others is Very Important
  WARNING You can be killed or seriously injured if you don’t follow instructions.

RATING DATA

Rating Data

1. Nominal capacity C5:
2. Nominal voltage:
3. Discharge current:
4. Nominal S.G. of electrolyte* Type PzQ:
5. Rated temperature:
6.  Nominal electrolyte level:

Will be reached within the first 10 cycles.

• See type plate
• 2.0 V x no. of cells
• C5 /5h
• 1.32 kg/l
• 30°C
• Up to electrolyte level mark ”max.”

CHARGED BATTERIES

Commissioning Filled and Charged Batteries

• The battery should be inspected to ensure it is in perfect physical condition; the battery harness must have reliable contact and must be connected with correct polarity. Otherwise the battery, vehicle or battery charger may be damaged.
  For the assembly of cables and harness cables, only use the original bolts. Attach the harness to the strain release cable clamp.
  Harness and connector bolts should be tightened to the following torque settings:

  • M 10 connector 25 ± 2 Nm

Operation

• EN 62485-3 “Safety requirements for secondary batteries and battery installations-Traction batteries” is the standard, which applies to the operation of traction batteries in industrial trucks.
• Bolts with thread lock may be used up to 5 times. For safety reasons, new bolts with thread lock
  are recommended. In case the interval between delivery (see manufacturing date on type plate) and commissioning is longer than 8 weeks or the electrolyte level sensor float indicator is indicating low electrolyte level (see table Filling Level Sensors), the electrolyte level must be checked. For removal of the water refilling plugs, only the appropriate tool must be used. Otherwise, the floats of plugs may be permanently damaged, which can cause overflow of the electrolyte. If the electrolyte level is below the top of the separator, it must first be topped up to this height with purified water (IEC 62877-1: 2016). The battery is then charged (see Charging section). The electrolyte should be topped up to the specified level with purified water.

Discharging

• Ensure that NO ventilation holes ARE sealed or covered. Electrical connections (e.g. plugs) must only be made or broken in the open circuit condition. To achieve optimum life for the battery, operating discharges of more than 70% of the rated capacity must be avoided (deep discharge). This corresponds to an electrolyte-specific gravity of 1.16 kg/l at 30°C at the end of the discharge. Discharged batteries must be recharged immediately and must not be left discharged. This also applies to partially discharged batteries. The discharge indicator on the truck/vehicle must be set correctly. The setting depends on the discharge indicator brand and must be equivalent to a discharge with a current of I_5 to a final voltage of 1.92Vpc for 70% DOD. Please refer to EnerSys® application engineer in case of AGV applications.

CHARGING

• Charging
  Only direct current must be used for charging. For IRONCLD® batteries, procedures in accordance with EN 41773-1 and EN 41774 are permitted. All batteries with a nominal energy >12kWh should be recharged with Air mixing profiles. Connect the battery to an assigned charger, suitable for the rating and specification of the battery (e.g. cable cross section, etc.), in order to avoid overloading of the electric cables and contacts, unacceptable gassing and the escape of electrolyte from the cells. In the gassing stage, the current limits given in EN 62485-3 must not be exceeded. If the charger was not purchased together with the battery, it is best to have the suitability of the charger, cables and plugs checked by the manufacturer’s service department. When charging, proper provision must be made for venting the charging gases. Truck doors, battery container lids and battery compartment covers must be opened or removed. During the charge in the truck, those from the manufacturers’ specified vents must be opened. In all cases, the ventilation must comply

Equalizing Charge

• Equalizing charges are used to safeguard the life of the battery and to maintain its capacity. They are necessary after deep discharges, repeated incomplete recharges, and charges to an IU characteristic curve. Equalizing charges are carried out following normal charging. The charging current must not exceed 5 A/100 Ah of rated capacity (end of charge— Charging). Watch the temperature! with EN 62485-3 standard. The vent plugs should remain on the cells and be kept closed. With the charger switched off, connect the battery, ensuring that the polarity is correct (positive to positive, negative to negative). Then switch on the charger.
• During the charging process, the temperature of the electrolyte rises by about 10°C, so charging should only begin if the electrolyte temperature is below 45°C. The electrolyte temperature of batteries should be at least +10°C before charging, otherwise a full charge cannot be achieved. A charge is finished when the specific gravity of the electrolyte and the battery voltage have remained constant for two hours. EnerSys® chargers automatically indicate end of charge. Batteries fitted with electrolyte circulation system: in case a pump fault is indicated, check that the piping system is connected and examine the piping circuit for leaks or defects (see “Annually” in the Maintenance section). The air pipe should never be removed during charge.

Temperature
An electrolyte temperature of 30°C is specified as the rated temperature. Higher temperatures shorten the life of the battery; lower temperatures reduce the capacity available. 55°C is the upper temperature limit and is not acceptable as an operating temperature.

Electrolyte

•  The rated specific gravity (S.G.) of the electrolyte is related to a temperature of 30°C and the nominal electrolyte level in the cell in fully charged condition.
• Higher temperatures reduce the specified gravity of the electrolyte, lower temperatures increase it. The temperature correction factor is -0.0007 kg/l per °C, e.g. an electrolyte-specific gravity of 1.31 kg/l at 45°C corresponds to an S.G. of 1.32 kg/l at 30°C. The electrolyte must conform to the purity regulations in IEC 62877-2: 2016.

MAINTENANCE

• Maintenance
• Daily
• Charge the battery after every discharge.
• The electrolyte level must not fall below the top of the separator or the electrolyte ”min” level mark. DO NOT ADD WATER IN THE FIRST 10 CYCLES.

Filling Level Sensors
In the case of batteries with filling level sensors, the LED should be observed daily.

• Do not top up the cells during the first 10 cycles, even when electrolyte level sensor shows a red blinking LED.
• Check the electrolyte level by the position of the float indicator of the water filling plug and top up with demineralized water at the end of the charge. Since the display always refers to a selected reference cell, please also pay attention to the additional instructions below under “Monthly”.
• Weekly
• Visual inspection after recharging for signs of dirt and mechanical damage to all component parts of the battery. Pay particular attention to the battery charging plugs and cables. For special applications with charge with a IU characteristic curve an equalizing charge must be carried out (see Equalizing Charge).
• Monthly
• At the end of the charge, the voltages of all cells should be measured with the charger switched on, and recorded. After charging has been completed, the electrolyte density and electrolyte temperature as well as the filling level (when filling level sensors are  used) of all cells are to be measured and recorded.
• If significant changes from earlier measurements or differences between the cells are found, further testing and maintenance by the service department should be requested. This should be done following a complete charge and a minimum of 2 hours’ rest time.
• Measure and record :
  • Total voltage
  • Voltage per cell
  • If the voltage readings are irregular, also check the
  • S.G. of each cell

Annually

• In accordance with EN 1175-1, at least once per year, an electrical specialist must check the insulation resistance of the truck and the battery. The tests on the insulation resistance of the battery must be conducted in accordance with EN 1987-1. The insulation resistance of the battery thus determined must not be below a value of 50 ohms per voltt of nominal voltage, in compliance with EN 62485-3.
• For batteries up to 20 V nominal voltage, the minimum value is 1,000 ohms.
• Batteries fitted with electrolyte circulation system: the filter of the air pump must be checked at least during the annual maintenance, and eventually must be cleaned or replaced. Depending on the environment, you may need to perform a filter check more frequently than once per year. Earlier replacement of the filter is necessary if for undefined reasons (no leaks in the air pipes) the defect signal of the air mixing system on the charger or on the battery (on DC air pump or remote signal) is illuminated. During the annual maintenance, check the correct operation of the air pump.

Care of the Battery

• The battery should always be kept clean and dry to prevent tracking currents. Cleaning must be done in accordance with the ZVEI code of practice “The Cleaning of Vehicle Traction Batteries”. Any liquid in the battery tray must be extracted and disposed of in the prescribed manner. Damage to the insulation of the tray should be repaired after cleaning, to ensure that the insulation value complies with EN 62485-3 and to prevent tray corrosion. If it is necessary to remove cells, it is best to call in EnerSys® service for this. Never use (apply) mineral grease on the battery; the sealing material of the terminal is incompatible and it can be permanently damaged. If necessary, use (apply) silicone grease containing TPFE.

STORAGE

Storage
If batteries are taken out of service for a lengthy period, they should be stored in a fully charged condition in a dry, frost-free room. To ensure the battery is always ready for use, a choice of charging methods can be made:

1.  Monthly equalizing charge as described in “Equalizing Charge”, or
2.  Float charging at a charging voltage of 2.29 V x the number of cells.

The storage time should be taken into account when considering the life of the battery.

Malfunctions

• If malfunctions are found on the battery or the charger, EnerSys® service should be called in immediately. The measurements taken in Monthly Maintenance will facilitate fault finding and their  elimination.
• A service contract with Enersys will make it easier to detect and correct faults in good time.

Standard and Optional Equipment

Water Refilling System

• Application
  • The water refilling system is used to automatically maintain the nominal electrolyte levels. The charging gasses escape through the vent on each cell. NO WATERING IN THE FIRST 10 CYCLES.
• Function
  • A valve and a float together control the topping-up process and maintain the correct water level in each cell. The valve allows the flow of water into each cell and the float closes the valve when the correct water level has been reached. For fault-free operation of the water refilling system, please note the instructions on the next page.

WATER REFILLING SYSTEM

• Manual or Automatic Connection
  The battery should be topped up shortly before completion of a full charge, as at this point the battery has reached a defined operational state resulting
  in satisfactory electrolyte mixing. Filling takes place when the connector (7) from the tank is connected to the coupling (6) on the battery.

• If manual connection is used, the battery should only be connected to the filling system once per week.

• If automatic coupling is used (with a magnetic valve controlled by the charging apparatus), the charger main switch selects the correct moment for filling. NOTE: In this case we recommend water refilling at least once per week to ensure the correct level of the electrolyte.

• In multiple shift and warm ambient temperature operations, it may be necessary to have shorter topping-up intervals.

• Filling Time
  Filling time depends on the utilization rate and the corresponding battery temperature. Generally speaking, the top-up process takes a few minutes and can vary according to the battery range.

• Working Pressure
  The water refilling system should be installed in such a way that a water pressure of 0.2 to 0.6 bar is obtained (with at least 2 m height difference between the upper edge of the battery and the lower edge of the tank). Any deviation from this means that the system will not function properly.

• Purity
  The topping up water must be purified. The water used to refill the batteries must have a conductance of not more than 30 μS/cm. The tank and pipes must be cleaned before operating the system.

• Pipe System on the Battery
  The pipe system to the individual battery cells must follow the battery’s electrical circuit. This reduces the risk of current leakage in the presence of electrolytic gas causing an explosion (EN 62485-3). A maximum of 20 cells may be connected in a series.
  The system should not be modified in any way.

• Working Temperature
  In winter, batteries fitted with a water refilling system should only be charged or refilled in a room temperature above 0°C.

• Flow Control
  A flow indicator built into the water supply pipe to the battery monitors the filling process. While filling the water, flow causes the built-in disc in the flow indicator to turn.
  When all the plugs are closed, the disc stops, indicating that the filling process is complete.

1. Tank
2. Outflow connector with ball valve
3.  Plug with magnetic valve
4. Plug with ball valve
5. Flow control
6. Coupling
7. Connector
8.  Battery charger
9. Charger main switch

ELECTROLYTE CIRCULATION SYSTEM

Electrolyte Circulation System

• Application
  The electrolyte circulation system is based on the principle of pumping air into the individual battery cells. This system prevents electrolyte stratification and the battery charge is optimised. The electrolyte circulation is particularly beneficial for short charge times, boost or opportunity charging.

• Function
  The electrolyte circulation system consists of a pipe system fitted in the cells. A diaphragm pump is fitted in the charger or separately mounted on the battery or vehicle. This diaphragm pump sends a low rate airflow into each cell, creating a circulating air stream inside the cell box. The air stream is continuous or pulsed, depending on the battery voltage and pump type. The air supply is adjusted in accordance to the number of cells in the battery.
  The pipe system to the individual battery cells must follow the existing electrical circuit. This reduces the risk of current leakage in the presence of electrolytic gas causing an explosion (EN 62485-3).

• Use with Separate Pipe System
  Air is supplied when the charger pipe system is connected to the battery pipe system (with blue ring).
  Use with Automatic Connection of the Pipe System Connecting the charge plug to the integrated air supply automatically supplies air to the battery.

• Maintenance of Air Filter
  Depending on the working conditions, the pump air filter should be changed at least once a year. In work areas with high levels of air pollution, the filter should be checked and replaced more frequently.

• Repair and Maintenance
  The system must be checked for leakage. The charger will display an error message to indicate leakage. Sometimes in the case of leakage, the characteristic charging curve is switched over to the characteristic standard curve (without electrolyte circulation). Faulty parts and faulty pipe sections must be replaced. Only EnerSys® original spare parts may be used, as these are designed for the pump air supply and will ensure correct functioning of the pump.

Wi-iQ® Battery Monitoring Device

• Wi-iQ® battery monitoring device will provide indications according to the table below.
• Tricolour LED
  • Green blinking = hardware OK
  • Blue rapid blinking = wireless identification
  • Red blinking = temperature warning > 55°C
• Blue LED
  • Rapid blinking = wireless identification
  • Slow blinking = voltage balance warning
  • OFF flashing = electrolyte level OK
  • Light is on constantly = electrolyte level low
• The Wi-iQ monitoring device is the electronic device that communicates wirelessly to download the battery key information for better diagnostics and service. The device is fitted to a main DC cable on the battery to monitor and record the values of current, voltage, temperature and electrolyte level (via optional external sensor). The LEDs on the Wi-iQ monitoring device provide real-time status of battery’s condition. The information is transferred to the PC via USB by wireless communication.

Operation

• The Wi-iQ® monitoring device is suitable for use on all battery technologies. Voltage range is 24V – 120V. The PC software program can analyze the data: state of charge, temperature warnings and low electrolyte level warnings.

Wi-iQ® BATTERY

• Clear Visibility
  Selecting the Exception & Detailed Reports will provide information on the condition of your battery and any actions that are necessary. Wi-iQ Report will quickly enable you to get a handle on your battery fleet charging and discharging characteristics. With information by battery family (truck type), you can see depth of discharge charts, cycles, charging and much more.

• Very Easy to Use
  Plug in USB modem to the PC; scan the Wi-iQ battery monitoring device close to you and select the one you need to be connected to, then upload the data. Wi- iQ Report is a PC software running on Windows. A USB wireless key is used for downloading Wi-iQ data in to a SQL database.

Declaration of Conformity

• ENERSYS SARL Rue Alexander Fleming ZI Est -CS 40962 F-62033 Arras Cedex- France declares under our sole responsibility that the product:
• Product Name: Wi-iQ3
• Models: W3-100 WCS-1 WCS-2 WCS-3
• to which this declaration relates, is in conformity with the following normative European and International standards:
• EMC Regulations 2016 (S.I. 2016/1091)
• Directive 2014/30/EU:
• Electromagnetic compatibility
• BS EN 12895 : 2015 / Al : 2019
• Directive 2011/65/EU:
• RoHS
• Radio Equipment Regulations 2017 (S.I. 2017 /1206)
• Directive 2014/53/EU:
• ETSI EN 301489-1 V2.1.1 (2017)
• ETSI EN 301489-17 V3.1.1 (2017)
• ETSI EN 300 328 V2.2. 2 (2019)
• Date Name : 28/10/2022 :
• David Lacombe Title : Senior Director Engineering Electronics Systems
• Signature

Declaration of Conformity

• ENERSYS SARL Rue Alexander Fleming ZI Est -CS 40962 F-62033 Arras Cedex- France declares under our sole responsibility that the product:
• Product Name: Wi-iQ4
• Models:
  • WIIQ4-101
  • WIIQ4-102
  • WIIQ4-202 B84-132 884-232
• to which this declaration relates, is in conformity with the following normative European and International standards:
• Electrical Equipment
  • (Safety) Regulations 2016 (S.I. 2016/1101)
• Directive 2014/35/EU:
• MC Rag on 2016(81/20:61081
• Directive 2014/30/EU:
• Electromagnetic compatibility
• BS EN 12895: 2015 / Al : 2019
• Directive 2011/65/EU: • RoHS
• Radio Equipment Regulations 2017 (S.I. 2017 /1206)
• Directive 2014/53/EU:
• ETSI EN 301489-1 V2.2.3 (2019)
• ETSI EN 301489-17 V3.2.2 (2019)
• ETSI EN 300 328 V2.2. 2 (2019) Date Name Title : 28/10/2022 : David Letombe : Senior Director Engineering Electronics Systems
• Signature
• Subject to technical modification without any prior notice. E.&O.E.
  • Back to the manufacturer!
  • Batteries with this sign must be recycled.
  • Batteries that are not returned for recycling process must be disposed of as hazardous waste!
  • When using motive power batteries and chargers, the operator must comply with the current standards, laws, rules, and regulations in force in the country of use!

www.enersys.com
Subject to technical modification without any prior notice. E.&O.E.
© 2024 EnerSys. All rights reserved. Trademarks and logos are the property of EnerSys and its affiliates, except for Bluetooth and CE, which are not the property of EnerSys. Subject to revisions without prior notice. E.&O.E.
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